Process and machine for coating ophthalmic lenses

ABSTRACT

In a process and machine for coating a surface of an ophthalmic lens, the lens is manually loaded by the operator to a wash/dry station within an enclosure of the coating machine. Thereafter, the machine computer controls the entire process. The machine is closed to minimize the introduction of external contaminates into the machine. Positive pressure and filtration of air is initiated in the enclosure before washing the lens. The loaded lens is washed and dried at the wash/dry station. The dried lens is transferred to a coating station within the enclosure and coated. The coated lens is transferred to a curing oven within the enclosure and cured. The cured lens is then discharged from the curing oven and the machine for collection by the operator. The machine can simultaneously process three lenses, one in the wash/dry/coat section, one in the cure section and one at a pick-off station between the wash/dry/coat and cure sections of the machine. A coated and cured lens can be produced in approximately sixty seconds.

BACKGROUND OF THE INVENTION

This application claims the benefit of U.S. Provisional Application No.60/030,711, filed Nov. 8, 1996.

This invention relates generally to the coating of ophthalmic lenses andmore particularly concerns the automation of the lens coating process.

Present ophthalmic lens coating procedures include manual insertion ofthe lens into a washing chamber to be washed by hand or by use of a highpressure wash pump, drying the washed lens by manually holding the lensover a filtered compressed air jet, manually moving the dried lens to acoating apparatus in which the lens coating material is not recycled andthen manually transferring the coated lens to a curing oven which isgenerally inaccurately controlled by use of a stop watch andpotentiometer control.

These independent steps and the manner in which they are performedresult in a slow, labor intensive process which wastes coating materialand produces greater volume of hazardous waste material for disposal.The room in which these steps are performed must be environmentallycontrolled to minimize the risk of contamination during the process.

It is, therefore, an object of this invention to provide a process andmachine for the automatic cleaning, coating and curing necessary toapply a scratch resistant coating to an ophthalmic lens. Another objectof this invention is to provide a process and machine for coatingophthalmic lenses in a self-contained environment, eliminating the needfor a "clean" room. A further object of this invention is to provide aprocess and machine for coating ophthalmic lenses which minimizes theuse of hazardous or flammable solvents. Yet another object of thisinvention is to provide a process and machine for coating ophthalmiclenses that minimizes coating waste by recirculating coating. Stillanother object of this invention is to provide a process and machine forcoating ophthalmic lenses that reduces operator exposure to coating byencapsulating the coating. Another object of the invention is to providea process and machine for coating ophthalmic lenses that reducesoperator decisions by use of computer control to instruct lensprocessing parameters. Yet another object of this invention is toprovide a process and machine for coating ophthalmic lenses whicheliminates process steps by automatically replenishing the coatingsupply and prompting the operator when the available coating has beenexhausted. Still another object of this invention is to provide aprocess and machine for coating ophthalmic lenses which minimizes manualhandling of the lens. Another object of this invention is to provide aprocess and machine for coating ophthalmic lenses that affords accuratecontrol of the curing phase of the process. A further object of thisinvention is to provide a process and machine for coating ophthalmiclenses that facilitates operator adjustment of curing times inaccordance with the strength of the curing device.

SUMMARY OF THE INVENTION

In accordance with the invention, a lens coater is provided whichautomatically controls the lens coating process from the insertion ofthe lens into the washer to the removal of the lens from the curer.

The back or concave portion of the ophthalmic lens is coated in asoftware controlled coating machine. The lens is attached to a rotatingshaft on a slide conveyor having both lateral and vertical transferpaths. At the insertion end of the machine, the lens is mounted on theslide conveyor and above the washing and drying basin which issubstantially cylindrical.

The lens is washed by a high pressure jet of deionized water directed atthe radius of the concave lens surface while the lens is rotated at apreselected spin speed. As the lens rotates, the nozzle directing thewater jet at the concave surface of the lens is rotated over anapproximately 28 degree arc from the center of the lens toward the outerperimeter of the lens. The arc movement of the nozzle is controlled by astepper motor with a cam linkage that causes the nozzle to shiftoutwardly at a slow rate of speed and inwardly at a high rate of speedso as to minimize operating time. In one wash cycle, the nozzle rotatesoutwardly twice and inwardly once.

The basin also includes one air nozzle directed upwardly at the concavesurface of the lens and a second air nozzle directed inwardly toward theedge of the lens to apply breathable air from a tank at high pressure tothe lens while the lens is spinning at a preselected lens drying speed.In the drying process, the air nozzle directed at the concave surface ofthe lens is twice outwardly and once inwardly pivoted over the 28 degreearc by the cam linked stepper motor.

When the drying cycle is completed, the lens is vertically transferredout of the washing/drying basin and horizontally transferred to aposition above the coating basin. It is then vertically lowered into thecoating basin for the coating process. The coating is applied by anothernozzle under the control of the cammed stepper motor. In the coatingprocess, the lens is caused to rotate at predetermined coating speeds. Alow coating speed is used to dispense the coating from the nozzle to theconcave surface of the lens. A high speed rotation of the lens is usedwhen dispensing is complete to thin the coating. The operating speed ofthe cam is coordinated to the rotational speed of the lens so as topermit appropriate distribution of the coating material.

A coating material injection system distributes a specified quantity ofcoating material into the coating basin for a preselected number oflenses to be coated. That is, for one density of coating material, theunit may typically add 25 milliliters of coating material to the coatingbasin for every 588 lenses that are coated. For another density ofcoating material, 25 milliliters of coating material may be injectedinto the coating basin for every 392 lenses to be coated. These numbershave been found suitable in the preferred embodiment of the devicehereinafter described, but they could vary considerably. A cartridgeinjection system which meters the use of the machine by the quantity ofcoating applied is preferred. The cartridge injection system allows thecoating process to be changed by simply flushing the former coating outof the system and changing the cartridge. The cartridge contains asoftware pack which controls the operation of the system and thusprovides the user the ability to change the operating parameters of themachine by merely changing a cartridge. This is especially beneficial tothe user because upgrades to the machine can be made by simply providingto the user new cartridges containing the upgrade in the cartridgesoftware. An additional advantage is that, since the unit automaticallytimes the injection of coating from the cartridge into the basin inspecified small doses, preferably in the 25 milliliter range, if thecoating basin becomes tainted, only 25 milliliters of coating materialneed be replaced. Also, since the dosages are metered, the unit can givewarning to the operator as to when the machine is low in coatingmaterial and can even shut the machine down automatically to prevent thedry operation of the device if coating reaches a predetermined minimallevel. The injector includes a sensor for determining the level. Sincethe lens coater process is controlled by a stepper motor, preferablyinvolving 200 steps per revolution, the timing of the coating operationis extremely accurate.

The injection system employs a fluid containing tube which dispensesfluid in response to the drive of a plunger. An information pack isdisposed at the rear of the plunger with a probe at the rear of theinformation pack. A screw driven by the stepper motor drives the probe,information pack and plunger into the fluid cartridge on demand. Theprobe is electrically connected to the lens coater computer to providethe necessary data for system operation.

During the washing process, as the lens spins about the axis extendingapproximately through its center and transverse to the lens face, wateris applied to the concave face of the lens through the nozzle orifice,the pressure being determined by the orifice size and pump serving thesystem. The nozzle reciprocates for three wetting sweeps, movingoutwardly, inwardly and outwardly, after which water application isterminated. The nozzle then returns in one sweep to home at an inwardsetting directed approximately toward the center of the lens.

During the drying process, the upper drying nozzle directs air atapproximately 45 psi at the lower circumferential edge of the lens so asto remove a bead of water that forms along this edge. It has been foundmost effective that the air injected through this edge drying nozzle bedirected at an angle of approximately 30 degrees from vertical towardthis circumferential edge.

In the coating process, a dwell time is provided in which the lens spinsfor a period of time between the demand for coating material and theactual application of the coating material to the lens. An EEPROM allowsthe user to set the dwell time. This is important because, if the dwelltime is not correct, anomalies can result in the lens center.

During the washing and drying processes and the coating process, aslinger or cover mounted above the lens covers the open upper portion ofthe washing-drying basin so as to block the escape of mist from thewasher-dryer basin into other parts of the machine.

After coating, when the conveyor has vertically removed the lens fromthe coating basin it then further laterally transfers the lens to apick-off station until a traveling arm picks up the lens. After leavingthe lens, the washing-drying and coating conveyor or slide then returnsto its home position.

The pick-off arm delivers the lens to an oven through a lens receivingdoor which closes after the lens is received. A UV source is mountedabove a substantially parabolic reflector. Preferably, the lower portionof the reflector is substantially parabolic while the sidewalls are moreelliptical. The ultraviolet source is separated from the lens by a wirescreen and shutter and a quartz lens which maintains air purity betweenthe lens chamber and the UV source chamber. The receiving door maintainsprotection of the other portions of the coating machine from UV exposureand allows flow of clean air by convection. The exposure distancebetween the UV source and the lens is predetermined and a stepper motorcontrols the time of the UV system operation. This is far more accuratethan the stop watch/potentiometer control previously known. Anultraviolet sensor is also provided above the curing oven. The sensor,which transforms light to energy, maximizes the life of the UV sensorand measures the application of UV to the lens. Thus, the customer isable to monitor the UV level and, therefore, minimize the risk of damageto the lens. A shutter between the sensor and the oven reduces exposureof the sensor during unnecessary periods and therefore adds to thesensor life. When the curing of the lens is complete, the lens isdischarged to the operator through a discharge door of the curing oven.The shutter mechanism extends the life of the UV lamp. The sensingmechanism permits a determination of the UV actually applied to the lensrather than merely measuring the ultraviolet output of the lamp. Thecure time is user controlled so that if the UV lamp weakens, the curetime can be increased until the lamp can be replaced. The machinerequires calibration approximately once in ten years. The time for UVcuring can be established by the user/operator independently of thecontrol time determined by the cartridge software.

The lens coating process and machine can simultaneously handle threelenses, one on the washer-dryer and coater conveyor, one at the pick-offstation and one on the oven pick-off arm.

The fully automatic lens coating process and machine provide the highestlevel of lens coating technology and intelligence for a scratchresistant coating application. Only one coating is needed to coat hardresin, polycarbonate and high index lenses. New solids coatingtechnology recirculates the coating, eliminating coating waste. A singlemachine automatically cleans, coats, and cures lenses with the push of abutton. The preferred coating, contains no hazardous or flammablesolvents. Use of non-solvent coating eliminates unpleasant odors causedby solvent coatings. Waste disposal issues are eliminated. Use ofencapsulated coating drastically reduces operator exposure to coating.The software pack memory chip instructs the machine on lens processingparameters which reduces operator decisions. Automated coatingreplenishment eliminates processing steps. The coating dispensercartridge prompts the operator when the coating cartridge is empty. Abuilt-in display panel allows easy diagnostics of machine components.The self-contained cleaning system eliminates the need for a clean roomenvironment. Yields are improved through reduced operator handling oflenses. A preferred embodiment of the machine is typically no more than4 feet wide by 22/3 feet deep by 45/8 feet high and weighs less than 500pounds.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will become apparent uponreading the following detailed description and upon reference to thedrawings in which:

FIG. 1 is a front perspective view of a preferred embodiment of theexterior of the lens coating machine;

FIG. 2 is a rear perspective view of a preferred embodiment of theexterior of the lens coating machine;

FIG. 3 is a front perspective assembly view of a preferred embodiment ofthe interior of the lens coating machine with some components removed;

FIG. 4 is a perspective assembly view of a preferred embodiment of ahepa filter used to create a positive flow of air through the lenscoating machine;

FIG. 5 is a perspective assembly view of a preferred embodiment of aspin motor assembly and transport assembly of the lens coating machine;

FIG. 6 is a perspective assembly view of a preferred embodiment of alens holder of the spin motor assembly of FIG. 5;

FIG. 7 is a perspective assembly view of a preferred embodiment of thewash/dry and coating basin assemblies of the lens coating machine;

FIG. 8 is a perspective assembly view of a preferred embodiment of thewash/dry and coating basin assemblies of the lens coating machine;

FIG. 9 is a perspective assembly view of a preferred embodiment of thecam nozzle assembly for use with the basin assemblies of FIGS. 7 and 8;

FIG. 10 is a side elevation view of the cam-nozzle assembly of FIG. 9;

FIG. 11 is a perspective assembly view of a preferred embodiment of awash pump assembly of the lens coating machine;

FIG. 12 is a perspective assembly view of a preferred embodiment of aclean air supply assembly of the lens coating machine;

FIG. 13 is a perspective assembly view of a preferred embodiment of acoating pump assembly of the lens coating machine;

FIG. 14 is a perspective assembly view of a preferred embodiment of acoating tube of the lens coating machine;

FIG. 15 is a perspective assembly view of a preferred embodiment of acoating tube pump for use with the coating tube of FIG. 14;

FIG. 16 is a perspective assembly view of a preferred embodiment of acoat side valve assembly for the lens coating machine;

FIG. 17 is a schematic diagram of a preferred embodiment of thepneumatics of the coating pump of the lens coating machine;

FIG. 18 is a perspective assembly view of a preferred embodiment of thepick-off assembly of the lens coating machine;

FIG. 19 is a diagram of a preferred embodiment of the pneumatics of thecoat side components of the lens coating machine;

FIG. 20 is a perspective assembly view of a preferred embodiment of theupper chamber of the cure oven of the lens coating machine;

FIG. 21 is a perspective assembly view of a preferred embodiment of thelower chamber of the cure oven of the lens coating machine;

FIG. 22 is a perspective assembly view of a preferred embodiment of acooling fan assembly of the lower chamber of FIG. 21;

FIG. 23 is a perspective assembly view of a preferred embodiment of theultraviolet bulb enclosure of the cure oven of the lens coating machine;

FIG. 24 is a perspective assembly view of a preferred embodiment of theultraviolet sensor of the cure oven of the lens coating machine;

FIG. 25 is a perspective assembly view of a preferred embodiment of apick-off arm assembly of the ultraviolet curing oven of the lens coatingmachine;

FIG. 26 is a perspective assembly view of a preferred embodiment of thecure side valve assembly of the lens coating machine;

FIG. 27 is a schematic diagram of a preferred embodiment of thepneumatics of the cure side components of the lens coating machine;

FIG. 28 an elevation view of a preferred embodiment of the front of thecoat side electrical panel of the lens coating machine;

FIG. 29 an elevation view of the rear of the panel of FIG. 28;

FIG. 30 an elevation view of a preferred embodiment of the front of thecure side electrical panel of the lens coating machine;

FIG. 31 an elevation view of the rear of the panel of FIG. 30;

FIGS. 32A, 32B and 32C are an electrical interconnect diagram of thelens coating machine;

FIGS. 33A and 32B are an A.C. electrical layout diagram of the lenscoating machine; and

FIG. 34 is a flow chart illustrating the operation of the lens coatingmachine and method.

While the invention will be described in connection with a preferredembodiment, it will be understood that it is not intended to limit theinvention to that embodiment. On the contrary, it is intended to coverall alternatives, modifications and equivalents as may be includedwithin the spirit and scope of the invention as defined by the appendedclaims.

DETAILED DESCRIPTION General Physical Description and Operation

The coating machine hereinafter described is a self-contained, singleunit system designed for operator efficiency and ease of maintenance andpart replacement. The general arrangement of the machine is best seen inreference to FIGS. 1, 2 and 3. For descriptive purposes, looking at FIG.1, the machine is addressed as consisting of four quadrant-like sectionswhich, moving clockwise from the upper left, can be broadly referred toas the coat side hood section, the cure side hood section, the cure sidecabinet section and the coat side cabinet section.

Turning to FIG. 3, the coat side hood section contains a hepa filterassembly 10, a spin motor assembly 30, a spin motor transport assembly50, a wash/dry basin assembly 80, a coat basin assembly 100, a camnozzle assembly 110, a wash pump assembly 150, a clean air supplyassembly 170, a coating pump assembly 190, a coat side valve assembly230, a pick-off station assembly 270, a coat side electrical panel 600and a control panel 660. In the general operation of the coat side hoodsection components, the hepa filter assembly 10 provides a cleanenvironment for the coating process. A lens chucked to the spin motorassembly 30 is moved by the transport assembly 50 sequentially from thewash/dry basin assembly 80 where the lens is washed and dried to thecoating basin assembly 100 where the lens is coated to the pick-offassembly 270 where the lens is dechucked and held for transfer to thecure side hood section of the machine. The cam/nozzle assembly 110directs the distribution of water, air and coating to wash, dry and coatthe lens, respectively. The wash pump assembly 150, the clean air supplyassembly 170 and the coating pump assembly 190 supply the deionizedwater, air and coating necessary to wash, dry and coat the lens. Thecoat side valve assembly 230 provides the overall pneumatic control forthe coat side components. The control panel 660 permits operatorinterface with the machine.

The cure side hood section of the machine contains the ultravioletcuring oven assembly 300 including an upper chamber 310, a lower chamber330, an ultraviolet bulb enclosure 360, an ultraviolet sensor assembly390, a pick-off arm assembly 420, a cure side valve assembly 480, and acure side electrical panel 630. In the general operation of the cureside components of the machine, the coated lens is cured in the upperchamber 310 by the ultraviolet light passed from the ultraviolet bulbenclosure 360 in the lower chamber 330. A cooling fan assembly 337 inthe lower chamber 330 controls the temperature in the oven 300 toprolong the life of the UV bulb 376. The pick-off arm assembly 420collects the coated lens from the pick-off station assembly 270, bringsthe coated lens into the upper chamber 310 of the oven 300 for curingand elects the cured lens from the machine when the process is complete.The sensor assembly 390 monitors the strength of the ultraviolet source370. The cure side valve assembly 480 controls the operation of the cureside components.

Referring to FIG. 1, the hood 510 has a hepa filter door 511 whichprovides access during maintenance to change out the hepa fan 18 andprefilter 21. A finger guard 512 covers the inlet to the hepa fan 18.The operator chucks the lens to be coated to the spin motor 31 through alens inlet or access door 513. The cured lens is discharged for pick upby the operator through a lens outlet or discharge door 505 when theprocess is completed. A prewash bowl 514 is located below the accessdoor. An opening 515 permitting observation of and access to the messagescreen 661, start/stop keys 662 and 663, menu select key 664, alter key665 and next key 666 of the control panel 660 is in the front of thehood 510. Another opening 516 at the front of the hood 510 permitsaccess to the coating filter 200 and the tube 202 of the coating pumpassembly 190. Looking at FIG. 2, the back of the hood 510 includes aninlet protected by a fan guard 335 and an exhaust 344 for the coolingfan assembly 337, circuit breakers 672, 673, 674 and 675 for electricalpower, a removable panel 517 for access to the coat side electricalpanel 600 and a removable panel 518 for access to the cure sideelectrical panel 630. Tray recesses 521 and 522 in the top of the hood510 are used to store lenses which are to be coated or which havealready been cured by the machine. An emergency stop switch 513 at thefront left of the hood 510 permits the operator to interrupt theoperation of the machine at any time.

Returning to FIG. 1, the cure side cabinet section 524 of the machinecontains an odor eliminator 692 and mist collector (not shown). The coatside cabinet 525 contains deionized water (not shown) and a drain bucket(not shown). Accessories drawers 526 and 527 are provided above eachcabinet 524 and 525 for storage of supplies necessary to the operationof the lens coating machine. The hood 510 is hinged 528 at the back topermit access to the coat side and cure side components of the machineand a key lock 529 is provided in the hood 510 to assure that the hood510 will only be opened when machine repair or adjustment is necessary.The hood 510 should not be opened unnecessarily because the desired"clean" operating environment within the machine is achieved only afterthe hepa fan 18 has run for at least a twenty-four hour period after thehood 510 of the machine has been closed. Maintaining this cleanenvironment is essential to quality lens coating.

Description and Operation of Component Assemblies

Looking at FIG. 4, the hepa filter assembly 10 consists of a base 11which receives and supports the hepa filter 12 below a heater consistingof a heater block 13 in which a pair of pencil heaters 14 and a thermalfuse 15 are disposed. The filter 12 seals against the lowerface of thebase 11. The heater block 13 is held in place by a heater lid 16 whichis secured to the support 11 with a heater lid gasket 17 between. A fan18 seated on a fan gasket 19 on the heater lid 16 is disposed above theheater block 13. A prefilter pad 21 resting on a wire support 22 mountedin a prefilter holder 23 is bolted to the fan 18 with a seal 20 disposedbetween the filter 23 and the fan 18. The fan 18 draws air flow in adirection 24 from the prefilter pad 21 through the fan 18 and the heaterblock 13 into the hepa filter 12. The temperature of the air around thecoating basin 101 is critical because variations in viscosity will bedetrimental to adhesion of the coating to the lens. Therefore, a heatsensor 697 located proximate the coating basin 101 monitors thetemperature and controls the operation of the heater block 13 and pencilheaters 14. The hepa fan 18 operates whenever the machine is plugged inand creates a positive air flow through the machine and particularly inthe area of the coating basin assembly 100 to provide the desired cleanenvironment.

The spin motor assembly 30 is illustrated in FIGS. 5 and 6 and includesa spin motor 31 mounted with its rotational axis in vertical alignmenton a bracket 32 with a switch magnet 33 mounted on one side of thebracket 32 and a lift cylinder connector 34 mounted on the bottom of thebracket. A lens holder adapter 35 is mounted on the spin motor shaft 36and a slinger 37 is mounted on the adapter 35 by use of set screws. Asshown in FIG. 6, a magnet 38 slides into a lens holder adapter 39 andextends slightly above the lens holder adapter 39 for engagement withthe lens holder adapter 35 on the spin motor shaft 36. A suction cup 41for gripping the lens has a mounting portion insertable into the lensholder adapter 39. The suction cup 41, the adapter 39 and the magnet 38are secured together by a screw 42. Thus, the lens adapter can bemodified to accommodate various lens diameters by removing the screw 42,inserting an appropriately sized suction cup 41 into the adapter 39 andreplacing the screw 42. The lens holder adapter 39 is provided with apair of external annular grooves 43 and 44 for purposes to behereinafter explained.

The spin motor transport assembly 50 is also shown in FIG. 5 andconsists of a back plate 51 on which upper and lower long rails 52 and53 are secured in horizontal alignment. Upper and lower bearings 54 and55 slide on their respective rails 52 and 53 and a bearing tie block 56connects the two bearings 54 and 55. A rodless air cylinder 57 ismounted in horizontal alignment on the back plate 51 between the rails52 and 53. The tie block 56 is provided with a notch 58. A left hand airinlet elbow 59 admits air into the cylinder 57 to drive its piston tothe right and a right hand air inlet elbow 61 admits air into thecylinder 57 to move its piston to the left. The piston is connected to acylinder plate 62 which reciprocates along the exterior of the cylinder57 with the piston. A second plate 63 mounted to the first plate 62permits adjustment for tolerance with respect to other parts of the spinmotor transport assembly 50. A screw 60 threaded into the notch 58engages with an aperture in the second plate 63 so that the pistondrives the tie block 56. A short rail 64 is vertically aligned on thefront face of the tie block 56 and a short rail bearing 65 reciprocatesvertically on the short rail 64. A lift cylinder 66 mounted on a support67 has the upper end of its shaft 68 engaged with the lower face of theconnector 34 on the spin motor bracket 32 which is mounted on thebearing 65. Upper and lower air inlets 69 and 71 admit and release airto permit downward and upward movement of the lift cylinder shaft 68,respectively. Thus, the spin motor assembly 30 can be verticallyreciprocated on the short rail 64 in response to the operation of thelift cylinder 66 and can be reciprocated horizontally in response to theflow of air in the rodless air cylinder 57. An up/down switch bracket 72supports reed switches 73 and 74 which respond to the magnet 33 tosignal the upper and lower limits of motion of the short rail 64 of theCPU 614. Three additional reed switches 697, 698 and 699 shown in FIG.32 and mounted on the rodless air cylinder 57 cooperate with the magnet33 to signal the left, intermediate and right horizontal positions ofthe spin motor 31 to the CPU 614 as will hereinafter be explained. Aspacer 75 on the back of the back plate 51 spaces the outside electricalpanel 600 from the spin motor transport assembly 50.

Turning now to FIGS. 7 and 8, the wash/dry basin assembly 80 isillustrated. The wash/dry basin 81 is seated on the left side of a basinsupport 82 and has a neck 83 extending downwardly from its bottomthrough the support 82 for connection to an elbow 84 through which thebasin 81 is drained into a bucket (not shown) in the coat side cabinet525. A vent hole 85 is provided in the rear wall of the basin 81 with avent plug 86 disposed in the hole 85 and a vent shield 87 screwed to theplug 86 within the basin 81. The plug 86 is a mist collector connectedby a hose (not shown) to the odor eliminator 692 shown in FIG. 33 andlocated in the coat side cabinet 525. A screen 88 is disposed in thebottom of the basin 81 to guard the neck 83 to the drain. A lens guard89 is seated on four lens guard supports 91 extending upwardly from thebottom of the basin 81. The lens guard 89 is provided with a diametricslot 92 and a radial slot 93 for reasons hereinafter explained. The lensguard 89 is screwed to the supports 91 and prevents a lens from droppinginto the cam nozzle assembly 110. A rubber shield 94 with a concentricopening 95 through it is sandwiched between a retaining ring 96 and abasin cover 97 with a concentric opening 98 through it and serves as asplash guard over the basin 81. The shield 94 and ring 96 are seated inan annular flange 99 extending downwardly from the cover 97 and screwedin place. The cover 97 is seated on top of the basin 81 with the flange97 around the upper perimeter of the basin 81. The slinger 37 fits intothe cover opening 98 when the spin motor assembly 30 is at its lowestposition to complete the covering of the basin 81.

Continuing to look at FIGS. 7 and 8, the coat basin assembly 100includes a coat basin 101 which is seated on the right side of the basinsupport 82 with a reservoir 102 having a flat wall on one side extendingfrom the bottom of the basin 101 through the support 82. A basin screen103 is seated in the bottom of the basin 101 to guard the reservoir 102.The reservoir 102 stores coating material and typically is sized tostore approximately 100 milliliters of coating. A lens guard 104 screwedto four lens guard supports 105 has a diametric slot 106 for reasonshereinafter explained. The lens guard supports 105 are seated on thebottom of the basin 101 and support the lens guard 104 at an elevatedposition within the basin 101 to prevent a lens from dropping into thecam/nozzle assembly 110. A basin cover 107 having a concentric opening108 and a downwardly depending annular flange 109 is seated on the upperrim of the basin 101 with the flange 109 around the basin 101 andcooperates with the slinger 37 as described in relation to the wash/drybasin 81 to cover the coating basin 101.

Looking now at FIGS. 7 through 10, the cam nozzle assembly 110 is shown.A stepper motor 111 is mounted to a bracket 112 which is secured to themachine frame below the basin support 82. The motor 111 has a shaft 113to which is secured a cam 114, perhaps by set screws. The shape of thecam 114 is contoured to maintain constant application speed of coatingto the lens and facilitates rapid return to the home position when thestroke is completed. A cam follower 115 which traces the perimeter ofthe cam 114 is rotatably mounted on a cam arm 116. A wash basin tube 117extends horizontally through diametrically aligned holes at the bottomof the wash basin 81 with seals 118 and 119 preventing leakage from thewash basin 81. The tube 117 has an upwardly directed water nozzle 121secured in place by a cap 122. A switch arm 123 is fastened to the tube117 between the water nozzle 121 and the cam arm 116. The wash basintube 117 is journalled for rotation at one end in a first bearing 124and is connected at its other end to a coating tube 136 which isjournalled in a second bearing 125. The bearings 124 and 125 are boltedto the basin support 82. A slot 126 in the basin support 82 permits thecam to protrude through the base 82 to contact the follower 115. Acollar 127 mounted on the end of the tube 117 opposite the nozzle endmaintains the longitudinal position of the tube 117 between the brackets124 and 125. The deionized water path into the wash/dry basin 81 extendsfrom a bushing 128 through an elbow 129 to the end of the tube 117extending through the first bearing 124. Deionized water passes throughthe tube 117 and then upwardly through the nozzle 121 toward the lensthrough the slot 92 in the lens guard 89 in the wash/dry basin 81. Anupwardly directed air nozzle 131 is fixed to a lug 132 extendingradially from the tube 117 proximate the water nozzle 121 by a union133. A second air nozzle 134 is mounted inside the upper portion of thewash/dry basin 81 by a union 135 so as to be directed upwardly,preferably at approximately a thirty degree angle, at the edge of thelens in the wash/dry basin 81. The other end of the coating tube 136 hasa coating nozzle support 137 fastened to it. A coating nozzle 138 issecured in a substantially vertical position to the support 137 by aunion 139. A seal 146 prevents leakage of coating from the coating basin101 at the point of entry of the coating tube 136 into the coating basin101. The direction of the water nozzle 121, the air nozzle 131 and thecoating nozzle 138 which rotate radially on the axis of the tube 117 isset so that water, air or coating ejected from their respective nozzlesare directed proximate the center of a lens disposed within the wash/drybasin 81 or the coating basin 101 and will trace a radial path on thelens as the tubes 117 and 136 are rotated in the bearings 124 and 125.The upper air nozzle 135 is directed upwardly above the radial slot 93in the lens guard 89 at the edge of a lens inserted into the wash/drybasin 81 so as to dry the perimeter and edge of the lens. Coating isintroduced into the coat basin 101 through an aperture 140 in the coatbasin wall proximate the bottom of the coat basin 101. As can best beseen in FIG. 10, the nozzles 121, 131 and 138 are preferably positionedat an angle 141 which is approximately three degrees off vertical. Therotation of the tubes 117 and 136 are controlled by use of a magnet 144which is secured to the switch arm 123 by a bracket 143. A reed switch145 mounted on the basin support 82 cooperates with the magnet 144 tosignal the CPU 614 when the nozzles 121, 131 and 138 are in their homeposition.

Turning to FIG. 11, the water pump assembly 150 is illustrated. A waterpump 151 has its input 152 connected by a connector 153 to a deionizedwater input tube 154 which extends to the deionized water source (notshown) in the coat side cabinet 525. The output 155 of the water pump151 is connected through an L connector 156 to a tube 157, a connector158, a bushing 159 and a wash tube 161 to the bushing 128 of thecam/nozzle assembly 110 illustrated in FIG. 7. A solenoid valve 162which controls the operation of the water pump 151 by use of airconstantly applied through a connector 163 is connected to the waterpump 151 by a nipple 164. Input air is also constantly provided to thesolenoid 162 through an input 165, an elbow 166 and a nipple 167 as apilot assist to prime the solenoid 162. The operation of the solenoid162 is controlled by the CPU 614 to activate and deactivate the washpump 151 as required and any failure of the system is displayed on thecontrol panel display screen 661. A switch 701 in the hood 510 preventsoperation of the water pump 151 when the hood 510 is open. The pump 151is also provided with a drain connector 168 to allow water to escape inthe event of leakage.

Turning to FIG. 12, the clean air supply assembly 170 has a solenoidvalve 171 having an input connected by a bushing 172 to an inputconnector 173 which is mounted in the back of the machine for connectionto a source of air under pressure (not shown). The solenoid valve outputis connected through a bushing 174 and a T connector 175 to an airfilter 176, preferably in a range of 0.2 microns. The filter isconnected by an elbow 177 to a second T connector 178. One side 179 ofthe second T connector 178 is connected by a tube (not shown) to the upair nozzle 131 of the wash/dry basin 81 through the union 133 shown inFIG. 7. The other side 181 of the second T connector 178 is connected bya tube (not shown) to the second air nozzle 134 of the wash/dry basin 81via the union 135 shown in FIG. 7. The operation of the solenoid 171 iscontrolled by the CPU 614 to activate and deactivate the clean airsystem 170. A pressure switch 182 connected to the first T connector 175monitors the air pressure and is connected by cables 183 to the CPU 614which stops the coating process if the air pressure is too low to drythe lens and indicates the air pressure as a problem on the controlpanel display screen 661.

The coating pump assembly 190 is illustrated in FIGS. 13, 14,15 and 17.Looking at FIG. 13, the coating pump 191 has its output connectedthrough a connector 192 and an elbow 193 to a three-way solenoid valve194 having connectors 195 and 196 at its other two ports. A dose ofcoating is held in the pump chamber 197 and, when demand for coating ismade, the coating pump piston drives the coating from the chamber 197through the flow direction solenoid 194 and one of the connectors 195 toa coating filter 200 and a tube (not shown) to the coating nozzle 138shown in FIG. 7. The CPU 614 causes the directional solenoid 194 toalign with the coating nozzle 138 and simultaneously activates thecoating pump 191 under control of one of the valves of the valve pack232 when the horizontal intermediate reed switch 698 and the verticaldown reed switch 74 are closed. A switch 702 on the hood 510 preventsoperation of the coating pump assembly 190 when the hood 510 is open.When the coating distribution cycle is complete and the stepper motor 11has operated for a predetermined number of steps, the CPU 614 causes thesolenoid 194 to shuttle to connect the pump 191 to the solenoid 194 andthe second connector 196 to a drain connector 198 in the coating basinreservoir 102 shown in FIG. 7. The coating pump piston reversesdirection to draw coating out of the reservoir 102 of the coating basin101 to store the necessary dosage of coating in the chamber 197 for thenext coating cycle. The piston of the coating pump 191 is driven in thedesired direction by air injected and/or released through connectors 199and 201 to the pump 191 under the control of the coat side valveassembly 230 hereinafter discussed. The chamber 197 typically containstwenty-five milliliter doses of coating material. The original supply ofcoating material is contained in a coating tube 202 shown in FIG. 14. Apiston (not shown) within the coating tube 202 drives coating throughthe tube eject port 203 through a tube (not shown) connecting the ejectport 203 to the coating inlet aperture 140 in the coating basin 101 asshown in FIG. 7. A computer information pack 204 is attached by use of adouble backed adhesive pad 205 to an information pack mount 206 whichconnects to the back of the piston (not shown) and travels with thepiston (not shown) into the coating tube 202 as the quantity of coatingstored in the tube 202 decreases. Data contained in the information pack204 is read by a tactile touch probe 207 which is coupled by a probemount 208 to the shaft 209 of a linear stepper motor 211 which ismounted on a motor bracket 212 connected to the frame of the machine.The other end of the shaft 209 extends through a shaft tube support 213fixed to the motor 211 into a shaft tube 210 which extendslongitudinally about the shaft 209. An actuator mount 214 fastened tothe shaft 209 moves within the shaft tube 210 with the shaft 209 andbelow a longitudinal slot 215 on the upper wall of the shaft tube 210. Aswitch actuator 216 extends through the slot 215 and is connected to theactuator mount 214. A pair of limit switches 217 and 218 are mounted onswitch spacers 219 and 221, respectively, at opposite ends of the slot215 and cooperate with the actuator 216 to determine the longitudinalposition of the shaft 209 at maximum and minimum travel points. Inoperation, when the coating tube 202 is full, the probe 207 is in itsfully retracted position and the actuator 216 cooperates with therearmost limit switch 218 to signal the CPU 614 that the probe 207 is atits rearmost position and the tube 202 is full. As the unit dispensescoating into the coating basin 101, the stepper motor 211 operates todrive the shaft 209 forward and maintain engagement of the probe 207with the information pack 204. A level sensor 703 in the coating basin101 monitors the coating level and signals to the CPU 614 when thestepper motor 211 is to advance to drive the piston in the coating tube202 to distribute additional coating into the coat basin 101. Whendemand is made, the stepper motor 211 will operate for a sufficientnumber of steps to inject the desired quantity of coating into the coatbasin 101. If demand is made with failure to satisfy the requirement ofthe level sensor 703, the CPU 614 will indicate a failure on the displayscreen 661. When all of the coating has been ejected from the coatingtube 202, the actuator 216 will cooperate with the forward limit switch217 to indicate that the shaft 209 has reached its forward mostposition. When a predetermined number of injections have occurred, theCPU 614 causes the stepper motor to automatically return the shaft toits rearmost position with the actuator 216 cooperating with itsrearmost limit switch 218. In this condition, the empty coating tube 202can be removed and a new coating tube inserted. After insertion of thenew tube 202, the operator will cause the machine to resume operation.In addition to cooperating with the limit switches 217 and 218, theactuator 216 also serves, by cooperation with the slot 215, to preventthe shaft 209 of the stepper motor 211 from rotating.

The coat side valve assembly 230 shown in FIG. 16 includes a valve packmount 231 to which the valve pack 232 is secured. The valve pack 232includes five valves. One side of the valve pack 232 is connectedthrough a bushing 233, an elbow 234, a nipple 235 and another elbow 236to a filter regulator and gauge unit 237. The other side of theregulator 237 is connected through an elbow 238 to a hose connector 239.The other side of the valve pack 232 is connected through a bushing 241and a nipple 242 to a cross 243. One side of the cross 243 is connectedthrough a nipple 244 and an elbow 245 to a regulator with a gauge unit246. The other side of the regulator 246 is connected through a nipple247, bushing 248 and elbow 249 to a hose connection 251 which isconnected to the input connector 163 to the water pump solenoid valve162. A second leg of the cross 243 is connected to a hose connector 252which is extended to the cure side air supply and the final leg of thecross 243 is connected through an elbow 253 to a hose connector 254which is extended to the pilot valve fitting 165 of the water pumpsolenoid valve 162. A valve rack 255 mounted on the valve pack mount 231supports a plurality of pairs of flow control valves 256, 257, 258, 259and 260 (only one shown). The valves are held in place on the rack 255by a retainer 261 which secures the valves and the rack 255 against themount 231. Each pair of the valves is provided with inlet and outlethose connectors 262 and 263, the first connectors 262 extending by hosesto the connectors 265 of the valve pack 232. A label 264 applied to theface of the retainer 261 identifies the function of each of the valves.The valve pack 232 is also provided with another hose connector 264. Theoperation of the coat side valve assembly 230 will hereinafter beexplained.

The pick-off station assembly 270 is illustrated in FIG. 18. A bracket271 mounted on the frame of the machine supports a nonrotating liftcylinder 272 which reciprocates a lift platform 273 in response to theinjection of air into upper 274 and lower 275 hose connectors on eitherside of the piston (not shown) in the cylinder 272. A pair of lensbrackets 276 and 277, preferably opposed spaced apart U-shaped members,are fastened to the top of the lift platform 273 so that the upperhorizontal flanges 278 and 279 are reciprocated with the platform 273. Aswitch magnet 281 is fastened to the bottom of one of the brackets 276.A switch bracket 282 secured to the machine frame supports a pair ofreed switches 283 and 284 spaced apart at the upper and lower levelsattained by the magnet 281 when the platform 273 attains its upper andlower limits of motion. In operation, the platform 273 is normally inits upmost position in which the flanges 278 and 279 will engage in thetop groove 43 in the lens holder adapter 39 illustrated in FIG. 6. Whenthe spin motor assembly 30 has reached the pick-off station assembly 270so as to engage the adapter 39 in the flanges 278 and 279, the rightside reed switch 699 signals the CPU 614 to operate the cylinder 272downwardly to disengage the magnet 38 in the lens holder adapter 39 fromthe adapter 35 fixed to the shaft 36 of the spin motor 31 as shown inFIG. 5. Thus, the lens is de-chucked by the pick-off station assembly270 and held for subsequent chucking for transmission to the cure sideof the machine as will hereinafter be explained. When the lift platform273 is in its lowermost position, the magnet 281 cooperates with thebottom reed switch 284 to signal the CPU 614 to return the spin motorassembly 30 to its position above the wash/dry basin assembly 80.

The operation of the coat side valve assembly 230 is illustrated in FIG.19. The input air for the system is received through the filterregulator and gauge unit 237 and is delivered to the valves A, B, C, Dand E of the valve pack 232. The air is then distributed through thefirst valve 232A to the rodless actuator 57 of the spin motor transportassembly 50 through control valves 256a and 256b to cause the right andleft horizontal movement, respectively, of the spin motor 31. The secondvalve 232B serves the lift cylinder 66 of the spin motor transportassembly 50 through control valves 257a and 257b to cause the up anddown movement, respectively, of the spin motor 31. The input air is alsodistributed from the third valve pack 232C to the coating pump 191 ofthe coating pump assembly 190. The operation of this portion of thepneumatic system is shown in greater detail in FIG. 17. The three-waysolenoid valve 194 operates as earlier explained in relation to thecoating pump 191. The regulator 237 regulates the operating pressure ofthe system at approximately 60 psi to supply the valve pack 232. Anotherregulator 216 regulates the pressure applied to the pump 191 through thecontrol valve 258b to approximately 35 psi. The input through the othercontrol valve 258a to the pump 191 which retracts the piston camoperates at system pressure because the pressure is not critical to thecoating process. The fourth valve 232D also distributes air to controlvalves 259a and 259b to operate the nonrotating lift cylinder 272 of thepick-off station assembly 270. The fifth valve 232E distributes airthrough control valves 260a and 260b to open and close the access door513 of the machine. Finally, air from the input filter regulator andgauge unit 237 is distributed through the regulator 246 to the wash pumpsolenoid valve 162 which in turn causes the operation of the water pump151 of the wash pump assembly 150.

The upper chamber 310 of the curing oven 300 is illustrated in FIG. 20.A rectangular lens chamber 311 has an inlet door 312 and an outlet door313 which slide vertically to open and close passageways in adjoiningwalls proximate one corner of the lens chamber 311. The inlet door 312is operated by an air cylinder 314 which is mounted on the lens chambertop 315 by use of a cylinder bracket 316 and a cylinder mount 317. Theoutlet door 313 is operated by a second air cylinder 318 which is alsomounted on the lens chamber top 315 by use of a second bracket 319 andmount 321. The inlet and outlet doors 312 and 313 slide within doorguides 322 and 322 and 324 and 325, respectively. A magnet 326 isfastened to each of the doors 312 and 313 and reed switches 327 and 328are fastened to one of the door guides 322 and 324 of each door. Thereed switches 327 and 328 signal to the CPU 614 that the doors 312 and313 are closed to assure that the lens chamber 311 is exposed to anultraviolet source only when both doors 312 and 313 are closed.

The upper chamber 310 is seated on top of a cover plate 421 shown inFIG. 25 of the lower chamber 330 which is illustrated in FIG. 21. Arectangular housing 331 is supported on a base plate 332. The rear rightcorner of the housing is divided into a separate compartment by anelectrical component shield 333. A fan 334 mounted on the outer face ofthe left side rear wall draws input air to the lower chamber through afan guard 335 and a filter pad holder 336. A cooling fan assembly 337mounted on the base 332 in the front left corner of the housing 331 hasa horizontal air flow opening 338 in its top wall with a pair of angleirons 339 extending from front to rear of the top of the assembly 337 oneither side of the opening 338. A bracket 341 extends rearwardly andupwardly from the top of the cooling fan assembly 337 between the angleirons 339. A rectangular opening 342 is provided in the upper front wallof the housing 331 above the cooling fan assembly 337 and between theangle irons 339. A pair of spring catches 343 are mounted on the insideof the front wall of the housing 331 on either side of the rectangularopening 342. An exhaust tube 344 extends from the back of the coolingfan assembly 337 through the rear wall of the housing 331. Thus, thecooling fan 334 draws external air into the housing 331 along the inletpath 345 toward the rectangular opening 342 where it enters the coolingfan assembly 337 along a downward path 346 through the air flow opening338 and then into the exhaust tube 344 which directs it out of thehousing 331. Terminal blocks 347 (only one shown) and a terminal end cap348 for the electrical connection of the fans 334 and 359 and theballast 354 as shown in FIG. 33 are mounted on a rail 356 fastened tothe base plate 332 below the inlet of the fan 334 into the housing 331.The electrical compartment defined by the shield 333 contains a firstcapacitor 349 mounted to the base 332 by a pair of brackets 351 and asecond capacitor 352 mounted to the base 332 on a bracket 353. A ballast354 is mounted on the base 332 by a pair of brackets 355. The operationof the electrical system will hereinafter be explained. A green LED lens357 is provided in the upper left hand corner of the front face of thehousing 331. The upper edges of the housing 331 are aligned with gaskets358 to support the cover plate 421 of the lower chamber 330.

The ultraviolet bulb enclosure 370 is shown in FIG. 22. A bulb housingweldment 371 has a base and side walls with a plurality of apertures372. A substantially parabolic reflector 374 is seated in the weldment371 in concave position with the upper edges of the reflector 373 havingflanges 374 seated on the upper edges of the weldment 371. Preferably,the lower portion of the reflector 373 is parabolic and the side wallsof the reflector 373 are more elliptical. A pair of bulb brackets 375fastened to the front and rear walls of the weldment 371 support theultraviolet bulb 376 in longitudinal alignment within the reflector 373.A thermostat disk 378 fastened to the outer back wall of the weldment371 controls the operation of the cooling fan 334 in the lower chamber330 of the oven so that the fan 334 will not turn on until after thebulb 376 has warmed up typically at approximately 120 degrees F., andwill not shut off until after the bulb 376 has cooled down, also toapproximately 120 degrees F. A second thermostat disk 377 fastened tothe back of the bulb bracket 375 in front of the back of the weldment371 functions as a safety disconnect if the first thermostat disk 378fails to function and disconnects the ultraviolet bulb 376 atapproximately 250 degrees F. A connector 379 is mounted on the back of alower rear extension 381 of the weldment 371. A rectangular front face382 backed by a gasket 383 is fastened to the front of the weldment 371in spaced apart relationship established by standoffs 384. A knob 385fastened to the front of the front face 382 permits the operator toinsert and withdraw the ultraviolet bulb enclosure 370 into and from therectangular aperture 342 in the front wall of the lower chamber 330.With the enclosure 370 fully inserted, the gasket 383 seals the opening342 and assures the flow of cooling air through the enclosure 370. Asshown in FIG. 22, the interior of the cooling fan assembly 337 houses amuffin fan 359 which is mounted on a bracket 361 fastened to the sidewalls of the assembly 337. A fan ring 362 seated on top of the fan 359is covered by a fan guard 363. The fan 359 draws the flow of airdownwardly through the air flow opening 338 in the top of the assembly337. A connector 364 is mounted in the upwardly extending portion of thebracket 341 for bringing electrical power to the lamp 376. Preferably,the connector 364 has a self-aligning capability to assure properconnection when the bulb enclosure 370 is inserted into the lowerchamber 330.

The ultraviolet sensor assembly 390 is illustrated in FIG. 24. Amounting plate 391 with an aperture 392 through it is fastened on top ofthe upper chamber 310 of the oven 300. A sensor shutter 393 slidablypositioned over the aperture 392 is reciprocated by an air cylinder 394having its piston (not shown) driven by air injected into either end ofthe cylinder 394 through hose connectors 395 and 396. The cylinder 394is mounted on the plate 391 by a mounting bracket 397 and the shaft 398of the cylinder 394 is connected to the shutter 393 by means of anotherbracket 399. The operation of the cylinder 394 is controlled by the CPU614 by use of the solenoid valve 401. The air flow ports of the valve401 are connected by elbows 402 and 403 and hose connectors 404 and 405to the connectors 395 and 396 of the cylinder 394 through hoses (notshown). A sensor filter 406 mounted on a filter holder 407 is mountedwithin a sensor box 408. The ultraviolet sensor 409 is suspended withinthe box 408 above the filter 406 by use of spacers 411. The sensorconnector 412 extends outside of the box 408 through an aperture 413 inits sidewall. When the shutter 393 is opened, the sensor 409 detects theultraviolet energy level and the CPU 614 will not permit the operator tostart the process if the level is less than a predetermined thresholdestablished in the information pack 204.

The pick-off arm assembly 420 is shown in FIG. 25. The assembly 420 ismounted on the cover plate 421 of the lower chamber 330. The plate 421is seated on the gaskets 358 on top of the lower chamber 330 and arectangular aperture 422 is aligned above the ultraviolet bulb 376. Theaperture 422 is covered by a wire grid 423 mounted on a frame 424. Theunderside of the aperture 422 is surrounded by a gasket 425 and a quartzlens 426 is mounted against the gasket 425. The wire grid 423 shieldsagainst a lens dropping through the aperture 422 onto the quartz lens426. A shutter 427 is reciprocated beneath the quartz lens 426 on a pairof shutter guides 428 in response to the operation of an air cylinder429 which is mounted to the underside of the cover 421 on a mountingbracket 431. The rod 432 of the cylinder 429 is connected to the shutter427 by another bracket 423. A magnet 434 mounted on the shutter 427cooperates with a reed switch 435 mounted with a spacer 436 against theunderside of the cover plate 421 to signal the status of the shutter 427to the CPU 614. The upper chamber 310 of the oven 300 is mounted on thefront portion of the cover plate 421 as can best be seen in FIG. 3. Thepick-off arm assembly 420 is mounted on the back of the cover plate 421behind the upper chamber 310. A stepper motor 437 is mounted on thecover plate 421 by use of a bracket 438 with a gasket 439 between thebracket 438 and the mounting plate of the motor 437. A gasket 440 isalso provided between the bracket 438 and the cover plate 421. A timingpulley 441 is connected to the shaft 442 of the motor 437. A long shaft443 is journalled between two bearing brackets 444 and 445 mounted onthe cover plate 421. The long shaft 443 is journalled to the brackets444 and 445 by bearings 446 and 447. A second timing pulley 448 fixedproximate one end of the long shaft 443 is coupled to the motor shafttiming pulley 441 by a timing belt 449. The L-shaped lens pick-off arm451 is fixed to a linear actuator 452 which is in turn engaged on thelong shaft 443 to reciprocate axially along the long shaft 443 as thelong shaft 443 is rotated. Looking at FIGS. 20 and 25, the pick-off arm451 extends into the upper chamber 311 through an elongated slot 453 inthe back wall of the upper chamber 311 and the free end of the arm 451extends to be reciprocated through the opening covered by the entry door312. As shown in FIG. 25, a magnet 454 mounted on the pick-off arm 451with a spacer 455 cooperates with a home reed switche 456 and a limitswitch 457 mounted on a cam follower bearing guide 458 to signal theposition of the pick-off arm 451 to the CPU 614. When the CPU 614 isdetermining whether the stepper motor 437 is at its reference homeposition which occurs when the home reed switch 456 cooperates with themagnet 454, the reed switch 456 signals this condition to the CPU 614.The pick-off arm 451 continues to move from the reference home positionto its actual home position in response to a predetermined offsetcontrolled by the software of the CPU 614. At this home position, thelens center 459 of the pick-off arm 451 will be centered at theintersection of the axes centered on and transverse to the inlet andoutlet doors 312 and 313 of the upper chamber 310. When the limit switch457 cooperates with the magnet 456, the CPU 614 causes the travel of thepick-off arm 451 to be terminated. Thus, when a lens has been dechuckedfrom the spin motor assembly 30 by the pick-off station assembly 270 andis held between the flanges 278 of the lens brackets 276 at the pick-offstation 270, the pick-off arm 451 is extended out of the upper chamber310 by the motor 437 until the lens center 459 of the pick-off arm 451is centered above the magnet 38 of the lens adapter 39. The CPU 614 thencauses the pick-off station assembly 270 to be raised to engage themagnet 38 with the pick-off arm 451. The pick-off arm 451 is thenwithdrawn into the upper chamber 310, disengaging the lens from theannular groove 44 in the lens holder adapter 39. Looking again at FIG.20, when the lens which has been magnetically chucked to the pick-offarm 451 has been cured, it is ejected through the opening covered by theoutlet door 313 of the upper chamber 310. To accomplish this, a mount461 secured to the back wall of the upper chamber 310 over a horizontalaperture 462 centered on the transverse center axis of the outlet door313 and below the elongated slot 453 through which the pick-off arm 451extends. The mount 461 guides a pair of horizontally spaced apart shafts463 and 464 which are fixed at their front end to a push off member 465.The shafts 463 and 464 slide in bearings 472 secured in place in themount 461 by snap rings 473. An air cylinder 466 mounted to the mount461 has a rod 467 which extends through the mount 461 and connects atits free end to the push off 465. Thus, reciprocation of the cylinderrod 467 causes the push off 465 to be reciprocated in a path transverseto the path of reciprocation of the pick-off arm 451. The front of thepick-off 465 is provided with upper and lower tongues 468 and 469. Thelower tongue 468 engages with the bottom groove 44 in the lens holderadapter 39 and the upper tongue 468 engages with top of the adapter 39to extend the adapter 39 and the lens through the opening at the outletdoor 313 for collection by the operator. A magnet catch 471 fixed to thetop of the push off 465 cooperates with the magnet 38 of the adapter 39to assist in holding the adapter 39 in the push off 465. The CPU 614automatically causes the push off 465 to be operated after the pick-offarm 451 has returned to home position by use of the valve pack 484.

The cure side valve assembly 480 is illustrated in FIGS. 26 and 27. Amounting bracket 481 has an elevated front platform 482 and a tiltedrear platform 483 extending downwardly from the front platform 482. Avalve pack 484 is mounted on the front platform 482 and a valve rack 485supporting five pairs of flow control valves 486, 487, 488, 489 and 490(only one shown) is secured to the rear platform 483 by a valve retainer491. A label 492 disposed on the valve retainer 491 indicates thecomponents served by the respective flow control valves. Each of theflow control valves is provided with a pair of hose connectors 493 and494 and the valve pack 484 is provided with hose connectors 495 forconnection of the pneumatic system. Air pressure in the system iscontrolled by a regulator with gauge unit 496 with its input connectedthrough an elbow 497 to a hose connector 498 which is extended by a hose(not shown) to the connector 252 of the valve pack 230 shown in FIG. 16and its output connected through an elbow 499, a nipple 501 and anotherelbow 502 to the valve pack 484. A plug 503 is also provided to closethe air passage of the valve pack. Looking at FIG. 27, from theregulator 496 air is distributed through the valve pack 484 to each ofthe pairs of control valves 486, 487, 488, 489 and 490. The firstcontrol valves 486a and 486b cooperate with the solenoid valve 484D tocause the up and down strokes of the inlet door cylinder 314 of theinlet door 312 of the upper chamber 310. The second flow control valves487a and 487b cooperate with the solenoid valve 484C to cause the up anddown stroke of the outlet door cylinder 318 of the outlet door 313 ofthe upper chamber 310. The third flow control valves 488a and 488bcooperate with a third solenoid valve 484B to cause the rearward andforward strokes of the push-off cylinder 466 of the upper chamber 310.The fourth flow control valves 489a and 489b cooperate with a fourthsolenoid valve 484A to cause the opening and closing strokes of thecylinder 429 of the shutter 427 associated with the ultraviolet bulb376. The fifth flow control valves 490a and 490b cooperate with thefifth solenoid valve 484E to cause the up and down stroke of the aircylinder 504 which reciprocates the discharge door 505 in front of theoutlet door 313 of the upper chamber 310 as seen in FIG. 1.

The coat side electrical panel 600 is illustrated in FIGS. 28 and 29.The panel 600 contains a main power transformer 601, a spin motor driveboard 602, a main power relay 603, AC terminal blocks 604, a spin motorpower relay 605, a spin motor speed relay 606 and a spin motortransformer 607. A resistor 608 is provided as a dynamic brake for thespin motor 31. A drive board 609 is provided for the information pack204 and another drive board 611 provided for the cam/nozzle assembly110. DC terminal blocks 612 and a coat input/output board 613 areprovided. The panel 600 also contains the CPU 614 consisting of threestacked boards for controlling the coat and cure side electricalcomponents. As shown in FIG. 29, the back of the coat side electricalpanel 600 contains the main power supply 615 and the coat side steppermotor power supply 616 including AC in and DC out terminal blocks 617and 618, respectively.

The cure side electrical panel 630 is illustrated in FIGS. 30 and 31.The front side of the panel 630 holds a set of DC terminal blocks 631and a cure input/output board 632 with three solid state relay modules633 and eight input modules 634. The solid state relay modules 633control the operation of the ultraviolet bulb shutter 427, the operationof the exit door 313 of the oven 300 and the operation of the aircylinder 466 of the pick-off arm assembly 420. The input modules 634signal to the CPU 614 the condition of the inlet door 312 and the outletdoor 313 of the cure oven 300, the up limit switch 283 of the pick-offassembly 270, the forward limit switch 457, the ultraviolet bulb shutterdoor 427, the home switch 456 and the coating level falling belowminimum in the coating basin 101. The energization of the ultravioletbulb 376 is also controlled by the board 632. The front of the panel 630also contains voltage selector blocks 635 for the ballast 354, ACterminal blocks 636, a cure relay 637, a 25 amp ultraviolet bulb solidstate relay 638 and a cure drive board 639. Looking at the back of thepanel 630 as shown in FIG. 31, the panel 630 also contains a twenty-fourvolt 3.5 amp power supply 641.

The interconnect diagram of the lens coating machine is illustrated inFIG. 32. The CPU 614 is connected through the information pack PCB 609to the probe 207 which in turn contacts the information pack 204. TheCPU 614 is also connected through parallel ports 619 to the controlpanel 660. The utility ports 621 of the CPU 614 are connected to thecontrol panel speaker 667 and to the system clock battery 622. The I/Ocard of the CPU 614 is connected to the information pack drive board609, the coat input/output board 613, the cam nozzle assembly driveboard 611 and the cure side drive board 639. The I/O card of the CPU 614is also connected to the cure input/output board 632. The cureinput/output board 632 is connected to the inputs 651 and outputs 652 ofthe cure side assemblies and to the hood switch 653 connecting the cureside ultraviolet bulb solid state relay 638. The coat side of the coatinput/output board 613 is connected to inputs 654 and 655 of the coatside components of the lens coating machine and also output to thesolenoids 656 and 657 and to the coat side relays 605 and 606.

Turning to the lens coating machine A/C electrical schematic drawing ofFIG. 33, the input power terminals 671 are connected to the variousmachine electrical systems through a pair of eight amp circuit breakers672 and 673 and a pair of three amp circuit breakers 674 and 675. Thecircuit breakers 672 and 673 serve the cure oven blower fan 334 and thecure oven muffin fan 359. The fans 334 and 359 are connected in parallelwith each other and in series with the thermostat disk 378 of theultraviolet bulb enclosure 370. The cure blower fan 334 is alsoconnected to the capacitor 352 in the lower chamber 330 of the oven 300.The circuit breaker 672 is also connected through a normally opencontact 678 of the cure side relay 637 and a normally open contact 679of the solid state cure relay 638 and the circuit breaker 673 through anormally open contact 676 of the cure side relay 637 to the ballast 354of the ultraviolet bulb 376. The automatic thermostatic disk 377 of theultraviolet bulb enclosure 370 is connected between the ballast 354 andthe bulb 376. Thus, when the circuit breakers 672 and 673 are closed,the fans 334 and 359 operate in response to the operation of thethermostatic disk 378. In addition, when the cure side relay 637 isenergized, and the solid state relay 638 and the thermostat 377 permit,the ultraviolet bulb 376 will be energized. The circuit breakers 674 and675 provide power to the hepa fan 18 and to the temperature controlmodule 677. The circuit breakers 674 and 675 are also connected throughnormally open contacts 681 and 682 of the main control relay 603 to thecure side twenty-four volt power supply 641, the coat side twenty-fourvolt power supply 616 and the multi-level power supply 615 of the coatside electrical panel 600. The circuit breaker 674 is also connectedthrough the main control relay contact 681 and another circuit breaker683 and the circuit breaker 675 through the main control relay contact682 to the spin motor transformer 607. The secondary side of the spinmotor transformer 607 is connected to the spin motor drive board 602.The spin motor 31 is connected in parallel with the resistor 608 in thecoat side electrical panel 600 and a normally closed contact 684 of thespin motor power relay 605. This parallel circuit is connected to thespin motor drive board 602 by a normally open contact 685 of the spinmotor power relay 605 in the coat side electrical panel 600. The spinmotor drive board 602 is also connected to a normally closed contact 686and normally opened contact 687 of the spin speed control relay 606 tovariable resistors 688 and 689 to control the speed of the spin motor31. Finally, the spin motor drive board 602 is connected across anormally closed contact 691 of the spin motor power relay 605. Thus,when circuit breakers 674 and 675 are closed, the hepa fan 18 operatesand the temperature control module 677 is energized. When the maincontrol relay 603 is energized, the low voltage power supplies 641, 616and 615 are energized. If the fifth circuit breaker 683 is also closed,the spin motor transformer is energized to operate the spin motor 31through the drive board 602 and the speed control associated therewith.The odor eliminator 692 is also connected across the second pair ofcircuit breakers 674 and 675. The second pair of circuit breakers 674and 675 are also connected across a sixth circuit breaker 693 to theprimary side of the main transformer 601 located in the coat sideelectrical panel 600. The secondary side of the power transformer 601 isconnected through the normally closed emergency stop switch 523 and thenormally opened main power switch 694 to the main power relay 603 andthe cure side relay 637 which are connected in parallel. The secondaryside of the transformer 601 is also connected through normally openedcontacts 695 and 696 of the main control relay 603 to various coat sideand cure side components of the lens coating machine. These include themachine entry door solenoid 232E, the spin motor vertical positionsolenoid 232B, the spin motor speed control relay 605, the spin powercontrol relay 606, the wash pump solenoid 162, the coat pump solenoid232C and coat direction solenoid 194 connected in parallel with eachother, the horizontal direction right and left solenoid 232A, the lenspick-off solenoid 232D, the air dry solenoid 171, the cure oven entrydoor solenoid 484D, the cure oven ultraviolet bulb shutter solenoid484A, the cure oven exit door and machine discharge door solenoid 484C,E and the lens eject solenoid 484B.

MACHINE OPERATION

Looking at FIG. 34, the overall machine component operation can beunderstood. In the first step 701, the operator loads the lens onto thespin motor 31 and pushes the start key 662 on the control panel 660. Inthe next step 702, the spin motor 31 is lowered into the wash basin 81by the operation of the lift cylinder 66. When the lens has been fullylowered into the wash basin 81 until the slinger 37 covers the washbasin 81, then, in the next step 703, the water pump 151 is energized,the spin motor 31 is energized and the cam nozzle motor 111 is energizedso that deionized water is sprayed onto the rotating lens as the waternozzle 121 is directed across the radius of the lens. In the next step704, the water pump 151 is deenergized and the clean air solenoid valve171 operated to deliver clean air through the air nozzles 131 and 134while the cam nozzle motor 111 rotates the air nozzle 131 along theradius of the lens. In the next step 705, the spin motor 31 isdeenergized, the spin motor assembly 30 is raised out of the wash basin81 by the lift cylinder 66 and the rodless cylinder 57 transfers thespin motor assembly 30 to a position over the coating basin 101. In thisposition, the next step 706 occurs in which the lift cylinder 66 lowersthe spin motor assembly 30 to drop the lens into the coating basin 101until the slinger 37 covers the coating basin 101. The spin motor 31 isenergized, the coating pump 191 is energized and the cam nozzle motor111 is energized to rotate the coating nozzle 138 across the radius ofthe spinning lens. After the lens has been coated, in the next step 707the spin motor 31 is permitted to spin for a predetermined time, afterwhich the spin motor is deenergized and the lift cylinder 66 raises thespin motor assembly 30 to remove the lens from the coating basin 101.The rodless air cylinder 57 then causes the lens to be horizontallytransferred to the pick-off station assembly 270. In the next step 708,the lens is picked off the spin motor assembly 30 by the engagement ofthe lens holder adapter 39 with the lens brackets 276 and 277 of thepick-off station assembly 270. The pick-off station assembly 270 is thenlowered by the lift cylinder 272 to disengage the lens from the spinmotor assembly 30. The spin motor assembly 30 then returns to its homeposition over the wash basin 81 to receive another lens while the coatedlens remains at the pick-off station assembly 270. In the next step 709,the cure arm 451 is extended out of the oven 300 and above the magnet 38of the lens holder adapter 39. The lift cylinder 272 of the pick-offstation assembly 270 raises the lift platform 273 to engage the magnet38 with the pick-off arm 451. The cam motor 437 of the pick-off armassembly 420 then operates to withdraw the lens into the upper chamber310 of the cure oven 300 where it is exposed to light from theultraviolet bulb 376 as the cam motor 437 causes the lens to betraversed through the ultraviolet light path for a predetermined numberof steps of the motor 437. When curing is complete, in the final step710 the pick-off arm 451 is driven by the cam motor 437 to align thelens in its eject position through the cure oven outlet door 313 and theair cylinder 466 drives the push off 465 to eject the lens out of theupper chamber 310 of the oven 300 and out of the machine through thedischarge door 505 to the finish station of the lens coating machine.

To pre-clean the lens before lens coating, approximately 100 ml ofcleaning solution is poured into the pre-wash basin 514 of the machine,the lens is chucked on the machine suction cup 41, wiped with a circularmotion for three seconds on a sponge in the pre-wash basin 514 andloaded into the machine.

To begin the lens coating process, the power switch 694 on the left-handside of the machine is pressed. The user interface screen 661 willenergize, the blower fan 352 will start, the ultraviolet bulb 376 willbegin to warm for two minutes and, when the machine is initialized, theuser interface screen 661 will display that the coater and curer areREADY. The wet, pre-cleaned lens is then loaded into the machine. TheStart button 662 on the operator control panel 660 is pressed and themachine automatically washes and dries the lens, coats the lens, movesthe lens to the cure oven 300 for the cure cycle and extends the lensfrom the cure oven 300 for operator pick up.

To inspect coated lenses for faults before curing, after the machine isstarted, pressing the Menu key 664 on the operator control panel 660 twotimes will display the Mode Select Menu and pressing the Alter key 665will display the Select Mode field. A lens is pre-cleaned and the wet,pre-cleaned lens is loaded into the machine. Upon pressing the Startbutton 662 on the operator control panel 660, the machine automaticallywashes and dries the lens, coats the lens and moves the lenshorizontally back to the wash basin position. The lens is then removedand inspected for faults. If the coating is correct, the lens isrechucked and the Start key 662 pressed. The chucked lens moves directlyto the cure oven 300 for curing and removal. If the coating is notcorrect, the lens is cleaned and rechucked. The Stop key 663 is pressedto recoat the chucked lens. This inspection process can be continueduntil the Start key 662 is pressed.

To inspect coated lenses for faults after passing through the cure ovenbut without being cured, after the machine is started, the Menu key 664on the operator control panel 660 is pressed two times to display theMode Select Menu. The Alter key 665 is pressed until UNCURED displays inthe Select Mode field. A lens is pre-cleaned and loaded into themachine. The Start button 662 on the operator control panel 660 ispressed and the machine automatically washes and dries the lens, coatsthe lens, moves the lens through the cure oven 300 without being curedand extends the lens from the cure oven 300 for operator pick up andinspection. The lens is removed and inspected for faults. If the coatingis correct, the lens is rechucked. The Start key 662 is pressed and thechucked lens moves directly to the cure oven 300 for curing and removal.If the coating is not correct, the lens is cleaned and rechucked at thewash basin 81. The Stop key 663 is pressed to recoat the chucked lens.This inspection process can be continued until the Start key 662 ispressed.

SPECIFIC OPERATIONAL MODES

The machine hereinbefore described is a fully automatic lens coaterdesigned to produce a coated and cured lens every 60 seconds. Themachine has three operational modes:

(1) a Normal Mode used for automatic cleaning, coating and curing;

(2) an Inspect Mode used to inspect coated lenses before placement intothe curing oven; and

(3) an Uncured Mode used to inspect coated lenses after placement intothe curing oven but without curing so as to determine if the curing ovenis the cause of a contaminated lens coating.

Normal Mode Operation

After the machine is set up, the only operator participation is to chuckthe lens on the front end of the process, press a key, and pick up thecoated/cured lens on the back end. The bulk of the work is handled bythe lens coater operational process hereinafter described. Thepre-cleaned, chucked lens is immersed into the wash basin 81 whichcontains deionized water, spun, and dried with medical air. Afterdrying, the lens is moved horizontally to the coating basin 101. At thecoating basin 101, the coating nozzle 138 sprays coating onto a radiusof the lens as the lens is spun to cause an even application of coating.After coating, the lens is moved horizontally to the pick-off station270 where it is dechucked. The pick-off arm 451 extends through the cureoven inlet door 312 and picks off the chucked lens. The pick-off arm451, with the coated lens, retracts into the cure oven 300 and the inletdoor 312 closes. Light from an ultraviolet cure oven lamp 376 is passedby the lamp shutter 427 for a period of time that can be set using aNominal Cure Tie Menu at the control panel 660. After the nominal curetime expires, the cure oven outlet door 313 opens. The push-off 465extends the cured lens through the cure oven outlet door 313 and themachine discharge door 505 for operator pick up. The machine is readyfor another coating operation.

Inspect Mode Operation

The inspect mode of operation is accessed from the Mode Select Menu andis used to inspect coated lenses before placement into the curing oven300. If the coating is not correct, the lens can be cleaned with solventand reused.

In the inspect mode of operation, the pre-cleaned, chucked lens isimmersed into the wash basin 81, spun, and dried with medical air. Afterdrying, the lens is moved horizontally to the coating basin 101. At thecoating basin, the coating nozzle 138 sprays coating onto a radius ofthe lens as the lens is spun to cause an even application of coating.The coated lens is returned to the wash position where it can bedechucked for inspection prior to being cured. If the coating iscorrect, pressing the Start key 662 causes the chucked lens to be moveddirectly to the cure oven 300. If the coating is not correct, pressingthe Stop key 663 causes the chucked lens to be moved to the coatingbasin 101 to be recoated.

Uncured Mode Operation

The uncured mode of operation is used to determine if the curing oven300 is the cause of a contaminated lens coating. This mode of operationis accessed from the Mode Select Menu using the menu key 664. Theuncured mode of operation is identical to the physical movement of anormal mode lens coating operation, except that the ultraviolet lamp 376in the cure oven 300 is not energized to cure the coated lens. Thecoated lens can be removed from the cure oven 300 to determine if thecure oven 300 was the cause of contaminants.

Menus

The operator control panel 660 is the operator's interface with themachine. The control panel 660 is used to set the operational mode,begin the lens coating process, set operating parameters and diagnoseand troubleshoot the system. The menu structure of the operatorinterface includes a variety of menus which are accessed from theoperator control panel 660 using the menu key 664. These menus are usedto set machine operating parameters and to diagnose the operationalfunctionality of the machine. The machine control panel 660 includes avariety of separate menus which display in the menu/message displayscreen 661. The Menu key 664 is used to scroll through the menus of themachine in sequential order. On many of the separate operational menus,more than one machine parameter can be set. For example, the Time SetupMenu has two separate fields for time parameters, PRESENT TIME and TIMEFORMAT. The Next key 666 is used to toggle between the fields. After oneparameter is set, one press of the Next key 666 moves focus to the nextparameter. The Alter key 665 is used to change the current setting of amachine menu setting. For example, the default for the CURE TIME fieldon the Nominal Time Menu can be changed by pressing the Alter key 665after focus is on the CURE TIME. The Start key 662 is used to start thelens coating process. The Stop key 663 halts the lens coating process.

The Main Menu displays after the machine power switch 694 on theleft-hand side of the machine has been turned to the ON position and theinitialization sequence has been completed. This menu indicates theoperating status of the coater and curer as READY or NOT READY. From theMain Menu, one press of the Menu key 664 on the operator control panel660 will display the Coating Dwell Menu which controls the delay timebetween the start of the coating pump 191 and the start of the coatingapplication sweep of the coating nozzle 138 across the lens so as toeliminate anomalies the center of the lens. The range of dwell times istypically from 0.0 seconds to 0.9 seconds. From the Main Menu, twopresses of the Menu key 664 on the operator control panel 660 willdisplay the Mode Select Menu. From the Mode Select Menu, the threeseparate operating modes can be selected. From the Main Menu, threepresses of the Menu key 664 on the operator control panel 660 willdisplay the Charge/Purge Menu. After installation of the machine, theCharge/Purge Menu is used for two important functions before lenscoating can begin. The Coating Charge is typically a 25-minute cycle of10 second on/10 second off intervals used to charge or mix the coatingmaterial. Charging obtains an equal coating temperature which isnecessary for successful lens coating. Two 25-minute purge cycles arerecommended after installation of the machine. The coating purge is a 5minute cycle used to empty the coating reservoir 102 for cleaning. Whileat this menu, the coating cannot be auto-dispensed. The washing chargeis a 25 minute cycle of 10 second on/10 second off intervals used toremove air from the wash lines and charge the system. The washing purgeis a 5 minute cycle used to empty water from the lines before lineremoval. From the Main Menu, four presses of the Menu key 664 on theoperator control panel 660 will display the Cartridge Screen. TheCartridge Screen is used to replace the coating cartridge 202 when thelevel is low. When the Start key 662 is pressed, the cartridge plunger204 is withdrawn from the cartridge tube 202 to allow removal. Afterreturning to the Main Menu, the coating is replenished, if needed.

From the Main Menu, five presses of the Menu key 664 on the operatorcontrol panel 660 will display the Time Setup Menu. The machine timeformat can be set to military or standard time. The NEXT key 666 togglesbetween the time and format fields. When the cursor is in theappropriate field, the ALTER key 665 changes the time or format.

From the Main Menu, six presses of the Menu key 664 on the operatorcontrol panel 660 will display the first Diagnostic Display Menu. TheDiagnostic Display Menu includes four sub menus which can be accessed bysequentially pressing the NEXT key 666. The Diagnostic Display menuchecks the ability of the pixels of the screen 661 to turn on and off.The Diagnostic Display Menu is used to test the functionality of thedisplay screen 661. From the Main Menu, seven presses of the Menu key664 on the operator control panel 660 will display the first DiagnosticSensor Menu. The Diagnostic Sensor Menu includes four sub menus whichare accessible sequentially by pressing the NEXT key 666 on the operatorcontrol panel 660. The first Diagnostic Sensor Menu is used to monitorthe pre-wash water level according to the cap sensor. The position ofthe hood 510 is monitored by the hood sensor reed switch 702. The secondDiagnostic Sensor Menu is used to monitor the position of the limitswitches 217 and 218 of the information pack 204 and the coating sweephome reed switch 145. The third Diagnostic Sensor Menu is used tomonitor the pick-off up and down switches 283 and 284 of the pick-offstation 270. It also determines the home position of the cure ovenpick-off arm 451 near center of travel. The fourth Diagnostic SensorMenu is used to determine the ultraviolet output of the lamp 376 in thecuring oven 300. The range is 150% (normal) to 0% (nominal). A lowintensity percentage indicates the need to replace the ultraviolet bulb376, extend the cure time, or clean or replace the sensor 412.

From the Main Menu, eight presses of the Menu key 664 on the operatorcontrol panel 660 will display the first Diagnostic Output Menu. TheDiagnostic Output Menu includes eleven sub menus which are accessiblesequentially by pressing the NEXT key 666 on the operator control panel660. The first Diagnostic output Menu is used to test the portion of thelens discharge door 515. When the cursor is in this field, the Alter key665 toggles the lens discharge door 505 open or closed. The Door Sensorfield indicates the current position of the door 505. The secondDiagnostic Output Menu is used to test the performance of the verticalcylinder 66 and the up and down switches 73 and 74. The third DiagnosticOutput Menu is used to test the functionality (on/off) and speed of thedrive motor 31. The Next key 666 toggles the cursor position between thetwo fields. The fourth Diagnostic Output Menu is used to test thefunctionality (on/off) of the outer pump 151 and coating pump 191.However, the water pump 157 and coating pump 191 can be tested only whenthe machine senses that the hood 510 is closed. The fifth DiagnosticOutput Menu is used to test the hold pressure on both sides of therodless cylinder 57 and the left, intermediate and right switches 697,698 and 699. The sixth Diagnostic Output Menu is used to test thefunctionality of the lens pick-off assembly 270. The seventh DiagnosticOutput Menu is used to test the functionality of the air drying solenoid171 and sensor 182. The eighth Diagnostic Output Menu is used to testthe functionality of the inlet door 312 and the inlet door sensor 327.The ninth Diagnostic Output Menu is used to test the functionality ofthe cure oven exit door 313 and the exit door sensor 328. The tenthDiagnostic Output Menu is used to test the functionality of the lenseject cylinder 466. The door 313 opens and the lens is extended. Thecure torque sets voltages that control the low and high torque on thedrive of the cure oven stepper motor 437. The eleventh Diagnostic OutputMenu is used to test the functionality of the coating cartridge torqueadjustment of the information pack drive board 609.

From the Main Menu, nine presses of the Main key 664 on the operatorcontrol panel 660 will display the Cure Offset Menu. The Cure OffsetMenu is used to reposition or set the home position offset for aligningthe lens eject mechanism 465 with the lens holder 39. Proper alignmentof the cure arm 451 and the eject cylinder 466 is necessary for thestable ejection of lenses. A ±64 mm cure offset setting is preferred.

From the main menu, ten presses of the Menu key 664 on the operatorcontrol panel 660 will display the Coating Offset Menu. The CoatingOffset Menu is used to reposition or set the position of the coatingnozzle 138 in reference to the center of the lens.

From the Main Menu, eleven presses of the Menu key 664 on the operatorcontrol panel 660 will display the Nominal Time Menu. The Nominal TimeMenu is used to set the exposure time of the ultraviolet bulb 376 in thecure oven 300. The length of exposure can be increased or decreaseddepending on the Adjust field setting. The Next key 666 is used to setthe cursor in the Cure Time field, and the Alter key 665 is used toadjust the time. A nominal cure time setting of 20.6 seconds ispreferred.

From the Main Menu, twelve presses of the Menu key 664 on the operatorcontrol panel 660 will display the Version Menu. The Version Menudisplays the current version number of the software information pack 204in the machine.

From the Main Menu, thirteen presses of the Menu key 664 on the operatorcontrol panel 660 will display the Lens Usage Menu. The Lens Usage Menudisplays the total amount of lenses coated by the machine and the totalsince the lamp power up.

Thus, it is apparent that there has been provided, in accordance withthe invention, a process and machine for coating ophthalmic lenses thatfully satisfies the objects, aims and advantages set forth above. Whilethe invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives, modificationsand variations will be apparent to those skilled in the art and in lightof the foregoing description. Accordingly, it is intended to embrace allsuch alternatives, modifications and variations as fall within thespirit of the appended claims.

What is claimed is:
 1. A machine for automatically coating a surface ofan ophthalmic lens comprising:an enclosure having an inlet door forreceiving the lens to be coated and an outlet door for discharging thecoated lens; means in said enclosure proximate said inlet door forwashing and drying the lens surface; means in said enclosure spacedapart from said washing and drying means for coating the lens surface;means in said enclosure spaced apart from said washing and drying meansand said coating means and proximate said outlet door for curing thecoated lens surface: first means in said enclosure for transporting thelens from said washing and drying means to said coating means and fortransporting the lens from said coating means to a pick-up station insaid enclosure, said first transporting means having a carriagereciprocally slidable along vertical and lateral paths, means fordriving said carriage on said vertical path, means for driving saidcarriage on said lateral path, and a vertical rotatable shaft mounted onsaid carriage having a drive means connected to its upper end and achuck on its lower end for securing the lens to be coated with a concavesurface thereof facing approximately downwardly with a radial centerthereof approximately aligned with a rotational axis of said shaft;second means in said enclosure for transporting the lens from saidpick-up station to said curing means and from said curing means throughsaid enclosure outlet door; and a computer means controlling theoperation of said washing and drying means, said coating means, saidcuring means and said first and second transporting means forautomatically washing the received lens, drying the washed lens,transporting the dried lens, coating the surface of the transporteddried lens, transporting the coated lens, curing the coated surface ofthe transported lens and extending the cured lens through said enclosureoutlet door.
 2. A machine for automatically coating a surface of anophthalmic lens comprising:an enclosure having an inlet door forreceiving the lens to be coated and an outlet door for discharging thecoated lens; means in said enclosure proximate said inlet door forwashing and drying the lens surface, said washing and drying meanshaving a wash/dry basin and a water nozzle pivotally mounted within saidwash/dry basin to permit a substantially upwardly directed flow axisthereof to reciprocally trace a radial path relative to the lens; meansin said enclosure spaced apart from said washing and drying means forcoating the lens surface; means in said enclosure spaced apart from saidwashing and drying means and said coating means and proximate saidoutlet door for curing the coated lens surface; first means in saidenclosure for transporting the lens from said washing and drying meansto said coating means and for transporting the lens from said coatingmeans to a pick-up station in said enclosure; second means in saidenclosure for transporting the lens from said pick-up station to saidcuring means and from said curing means through said enclosure outletdoor; and a computer means controlling the operation of said washing anddrying means, said coating means, said curing means and said first andsecond transporting means for automatically washing the received lens,drying the washed lens, transporting the dried lens, coating the surfaceof the transported dried lens, transporting the coated lens, curing thecoated surface of the transported lens and extending the cured lensthrough said enclosure outlet door.
 3. A machine according to claim 2further comprising a reservoir for receiving used water from saidwash/dry basin.
 4. A machine according to claim 2 further comprising areservoir storing fresh water delivery to said water nozzle.
 5. Amachine according to claim 4 further comprising a pump for ejectingwater from said reservoir through said water nozzle.
 6. A machineaccording to claim 5 further comprising a water filter connected betweensaid reservoir and said pump.
 7. A machine according to claim 2 furthercomprising means for driving said pivotally mounted water nozzle to arcsaid nozzle flow axis outwardly from approximately the lens center overa substantially radial path with respect to the lens surface.
 8. Amachine according to claim 7, said drive means comprising a steppermotor having a cam mounted on a shaft thereof and engaged with a camfollower on said nozzle.
 9. A machine according to claim 2 furthercomprising means for reciprocating said nozzle outwardly at a low speed,inwardly at a high speed and outwardly at said low speed to cause saidnozzle flow axis to three times trace a substantially radial pathrelative to the spinning lens.
 10. A machine according to claim 2, saidwashing and drying means further comprising:a first air nozzle pivotallymounted within said wash/dry basin to permit a substantially upwardlydirected flow axis thereof to reciprocally trace a radial path relativeto the lens; and a second air nozzle fixedly mounted within saidwash/dry basin with an inwardly and upwardly directed flow axis thereofapproximately intersecting a lower edge of the lens.
 11. A machineaccording to claim 10 further comprising a source of compressed airconnected through a valve to said air nozzles.
 12. A machine accordingto claim 10 further comprising means for driving said pivotally mountedfirst air nozzle to arc said nozzle flow axis outwardly fromapproximately the lens center over a substantially radial path withrespect to the lens surface.
 13. A machine according to claim 12, saiddrive means comprising a stepper motor having a cam mounted on a shaftthereof and engaged with a cam follower on said nozzle.
 14. A machineaccording to claim 10 further comprising means for reciprocating saidfirst air nozzle outwardly at a low speed, inwardly at a high speed andoutwardly at said low speed to cause nozzle flow axis to three timestrace a substantially radial path relative to the lens.
 15. A machinefor automatically coating a surface of an ophthalmic lens comprising:anenclosure having an inlet door for receiving the lens to be coated andan outlet door for discharging the coated lens; means in said enclosureproximate said inlet door for washing and drying the lens surface; meansin said enclosure spaced apart from said washing and drying means forcoating the lens surface, said coating means having a coating basin anda coating nozzle pivotally mounted within said coating basin to permit aflow axis thereof to reciprocally trace a radial path relative to thelens; means in said enclosure spaced apart from said washing and dryingmeans and said coating means and proximate said outlet door for curingthe coated lens surface; first means in said enclosure for transportingthe lens from said washing and drying means to said coating means andfor transporting the lens from said coating means to a pick-up stationin said enclosure; second means in said enclosure for transporting thelens from said pick-up station to said curing means and from said curingmeans through said enclosure outlet door; and a computer meanscontrolling the operation of said washing and drying means, said coatingmeans, said curing means and said first and second transporting meansfor automatically washing the received lens, drying the washed lens,transporting the dried lens, coating the surface of the transporteddried lens, transporting the coated lens, curing the coated surface ofthe transported lens and extending the cured lens through said enclosureoutlet door.
 16. A machine according to claim 15, said coating meansfurther comprising:a cartridge; a cylinder within said cartridgecontaining coating material; a piston for forcing coating material fromsaid cylinder into a tube communicating with an interior of said coatingbasin; and means for driving said piston into said cylinder.
 17. Amachine according to claim 16 further comprising a data storage devicemounted on said piston exterior to said cylinder.
 18. A machineaccording to claim 17 further comprising a probe mounted on said datastorage device.
 19. A machine according to claim 18 further comprising ascrew connected to said probe and said driving means comprising astepper motor connected to said screw for driving said piston, said datastorage device and said probe into said cylinder.
 20. A machineaccording to claim 15 further comprising means for driving saidpivotally mounted coating nozzle to arc said nozzle flow axis outwardlyfrom approximately the lens center over a substantially radial path withrespect to the lens surface.
 21. A machine according to claim 20, saiddrive means comprising a stepper motor having a cam mounted on a shaftthereof and engaged with a cam follower on said nozzle.
 22. A machineaccording to claim 15 further comprising means for reciprocating saidnozzle outwardly at a first speed and inwardly at a second speed fasterthan said first speed to cause said nozzle flow axis to twice trace asubstantially radial path relative to the lens.
 23. A machine accordingto claim 15 further comprising a sensor in said coating basin fordetecting a level of coating material in said basin.
 24. A machineaccording to claim 23, said computer means being responsive to a signalreceived from said sensor to cease operation of the machine when thecoating material is below a predetermined threshold level in saidcoating basin.
 25. A machine according to claim 23, said computer meansbeing responsive to a signal received from said sensor to automaticallyinject a quantity the coating material into said basin when said levelof coating material falls below a predetermined threshold level.
 26. Amachine according to claim 23 further comprising an indicator connectedto said computer means, said computer means being responsive to a signalreceived from said sensor to activate said indicator when said level ofcoating material falls below a predetermined threshold level.
 27. Amachine for automatically coating a surface of an ophthalmic lenscomprising:an enclosure having an inlet door for receiving the lens tobe coated and an outlet door for discharging the coated lens; means insaid enclosure proximate said inlet door for washing and drying the lenssurface; means in said enclosure spaced apart from said washing anddrying means for coating the lens surface; means in said enclosurespaced apart from said washing and drying means and said coating meansand proximate said outlet door for curing the coated lens surface, saidcuring means having a shell having a first door for receiving the lensand a second door for exiting the lens; first means in said enclosurefor transporting the lens from said washing and drying means to saidcoating means and for transporting the lens from said coating means to apick-up station in said enclosure; second means in said enclosure fortransporting the lens from said pick-up station to said curing means andfrom said curing means through said enclosure outlet door, said secondtransporting means having a first retractable arm in said curing meanshaving one end adapted for picking up the lens outside of said firstcuring means door and a drive means for extending and retracting saidfirst arm and the lens through said first curing means door; and acomputer means controlling the operation of said washing and dryingmeans, said coating means, said curing means and said first and secondtransporting means for automatically washing the received lens, dryingthe washed lens, transporting the dried lens, coating the surface of thetransported dried lens, transporting the coated lens, curing the coatedsurface of the transported lens and extending the cured lens throughsaid enclosure outlet door.
 28. A machine according to claim 27, saidsecond transporting means further comprising:a second retractable armtransverse to said first retractable arm having one end adapted fordisengaging the lens from said first retractable arm and for holding thedisengaged lens; and drive means for extending and retracting saidsecond arm and the lens through said second curing means door.
 29. Amachine according to claim 27,said curing means further comprising:anultraviolet light source; and a shuttered opening in the shell betweensaid ultraviolet light source and a lens site in said shell.
 30. Amachine according to claim 29, said drive means causing the lens totraverse a predetermined distance within a predetermined time.
 31. Amachine according to claim 30 further comprising means controlled bysaid computer means for closing said ultraviolet light source shutteredopening and for opening said enclosure outlet door, said drive meansbeing a stepper motor and said computer means causing activation of saidclosing and opening means upon completion by said stepper motor of athreshold number of steps.
 32. A machine according to claim 29, saidcuring means further comprising a reflector focusing said ultravioletlight on the lens.
 33. A machine according to claim 32, said reflectorhaving a substantially parabolic lower wall and substantially ellipticalside walls.
 34. A machine according to claim 29, said curing meansfurther comprising a wire screen disposed between said ultraviolet lightsource and the lens.
 35. A machine according to claim 34, said curingmeans further comprising a quartz lens disposed between said shutter andsaid wire screen.
 36. A machine according to claim 29, said curing meansfurther comprising:an ultraviolet light sensor; and a shuttered openingin the shell between said ultraviolet light sensor and said lens site.37. A machine according to claim 36, said computer means beingresponsive to a signal received from said ultraviolet light sensor toclose said light source shuttered opening when a predetermined thresholdlevel of ultraviolet light has been sensed.